important!! please read before installation

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important!! please read before installation
IMPORTANT!!
PLEASE READ BEFORE
INSTALLATION
DURING INSTALLATION, ENSURE THAT NO EXHAUST,
OIL, COOLANT, OR INTAKE COMPONENTS ARE
PLACING ANY STRESS ON THE MANIFOLDS.
DO NOT FORCE COMPONENTS TO FIT!
IF COMPONENTS NEED TO BE FORCED INTO POSITION,
SUCH AS THE DOWNPIPE BRACKETS WHERE THEY MEET
THE TRANSMISSION, THE MANIFOLDS WILL BE PLACED
UNDER ABNORMAL STRESS, WHICH WILL
RESULT IN CRACKING.
MANIFOLDS THAT SHOW SIGNS OF STRESS FROM
COMPONENT MISALIGNMENT WILL BE DENIED
WARRANTY COVERAGE.
Copyright 2008, AWE Tuning. No part of this document may be reused or duplicated without the express permission of AWE Tuning/Secor Ltd. All rights reserved. Rev 2.1
Page 1 of 3
AWE Tuning 2000-2002 Audi 2.7T
Tubular Exhaust Manifolds
FOR RACING USE ONLY
Congratulations on your purchase of the highest flowing, most exquisitely designed and
constructed Audi 2.7T exhaust manifolds on the market.
With the AWE Tuning tubular exhaust manifolds, we have eliminated the restrictive “log” design of the
stock manifolds. Our design utilizes T-304 stainless steel tubing, CNC cut flanges, and anti-reversion
collectors. The use of central collectors minimizes turbulence in the manifold, which maintains ultimate
exhaust gas velocity. Maximum gas velocity in the manifold promotes more efficient evacuation of the
combustion chamber, known as cylinder scavenging. The collector also works as a physical barrier to
prevent the exhaust gases from flowing backwards during cam overlap.
These key elements work together to result in very quick turbo spool up and efficient high rpm exhaust
flow. The AWE Tuning manifolds are the secret to the broad powerband of the AWE Tuning RSK04 2.7T
Turbo kit.
Your AWE Tuning manifolds have a special Swain Tech coating that allows even better thermal insulation properties than the stock double-walled manifold design. This proprietary coating allows the fitment of a physically larger overall dimension manifold without sacrificing under hood heat control. The
coating is a unique ceramic thermal barrier, commonly used for aerospace applications such as rocket
nozzles, missile nose cones, and jet turbine parts.
Installation of the AWE Tuning manifolds requires removal of the engine from the vehicle. These manifolds can be used with the factory K03 spec turbos, and are best suited for use with the balance of our
RSK04 2.7T turbo kit.
Parts list:
1
18
18
2
1
1
1
AWE Tuning tubular exhaust manifold set
Modified manifold stud
Manifold stud nut
Manifold to cylinder head gasket
Modified driver side heat shield
Modified passenger side heat shield
Modified driver side tubing bracket
Required specialty tools:
1
1
1
1
8mmx1.25 threaded stud remover/installer (Mcmaster.com tool part number 2769A14 works best)
8mmx1.25 thread tap
12mm swivel socket
13mm swivel socket
Copyright 2008, AWE Tuning. No part of this document may be reused or duplicated without the express permission of AWE Tuning/Secor Ltd. All rights reserved. Rev 2.1
Page 2 of 3
The tubing path of the AWE Tuning manifolds requires swapping out
the manifold studs to provide easier installation of the exhaust nuts.
Once the stock manifolds have been removed, soak the OEM manifold studs with penetrating oil in preparation for removal.
A stud removal tool is best for unthreading the studs from the cylinder head. Be very careful not to break the studs while removing.
Once the OEM studs are removed, chase the stud hole threads with
the tap, then thread the enclosed studs into the head until they bottom out. Install them with the cut end of the stud facing outwards
as in Figure 1. Tighten the included new exhaust nuts to 25Nm.
Figure 1
The dimensions of the driver side manifold requires the use of a
modified bracket for the intake tubing. After installing the manifolds,
install the included bracket as in Figure 2.
Figure 2
Figure 3
When tightening the manifold to turbo bolts, pay close attention to
the oil and coolant lines running in the area of the manifold tubing.
Ensure that there are several millimeters of clearance between the
lines and the manifolds by rotating the turbo slightly before tightening. Slightly bending the brackets for these lines to provide proper
clearance may also be required. If the manifolds are contacting
these lines, there will not be proper room to expand and contract
with heat, resulting in manifold cracks.
Figure 3
Figure 4 shows the final installed picture of the passenger side AWE
Tuning manifold. Note that both manifolds reuse the stock EGT sensors, as well as the stock socket head bolts for the turbos. Be sure to
replace the gasket between the manifolds and the turbos, and torque
the socket head bolts to 25Nm. Use the included modified OEM heat
shields during reinstallation of the engine.
PLEASE NOTE: WHEN INSTALLING THE EXHAUST, OILING,
COOLANT, AND INTAKE COMPONENTS, ENSURE THAT NO
STRESS IS PLACED ON THE MANIFOLDS. FORCING PARTS
TO FIT, SUCH AS THE DOWNPIPE BRACKETS WHERE THEY
MEET THE TRANSMISSION, WILL PLACE THE MANIFOLDS
UNDER STRESS, RESULTING IN CRACKS. MANIFOLDS THAT
SHOW SIGNS OF STRESS FROM COMPONENT MISALIGNMENT WILL BE DENIED WARRANTY COVERAGE.
Figure 4
If you have any questions regarding this product, please do not hesitate to contact us:
AWE Tuning
1-888-565-2257
[email protected]
Copyright 2008, AWE Tuning. No part of this document may be reused or duplicated without the express permission of AWE Tuning/Secor Ltd. All rights reserved. Rev 2.1
Page 3 of 3
AWE Tuning
199 Precision Dr
Horsham, PA 19044
215.658.1670
www.awe-tuning.com
Thank you for choosing A.W.E. Tuning as your performance automotive parts supplier. Please remember that a performance car is only as strong as its weakest link. Therefore, it is vital that you maintain
your vehicle to factory specifications.
Limited Warranty
The following warranty is valid only in the United States.
The Manufacturer’s full warranty applies to all products sold.
By installing or using the purchased product, the Consumer accepts this warranty.
Secor Ltd. (A.W.E. Tuning) warrants to the original retail purchaser (Consumer) against defects the
2.7T Tubular Manifold Set for a period of 1 year.
Upon verification of warranty coverage, A.W.E. Tuning will repair or replace the defective product at
their discretion, without charge. This is the only remedy the Consumer has for any loss or damage,
however arising, due to nonconformity in or defect of the product. This warranty does not cover consequential damage, loss of time or revenues, inconvenience, loss of use of vehicle, damage to the vehicle or components, or other incidental or indirect damage.
All warranties are void if the product was not installed by a certified auto mechanic, improperly serviced, modified, or used in a way not intended by the Manufacturer. Use of product in Motorsports or
Racing conditions is grounds for warranty denial. Motorsports and Racing is an inherently abusive operational condition, and it is impossible to warranty for this type of usage.
The Consumer is responsible for ensuring that the product is installed in a safe and proper manner,
and should cease usage of the product immediately if an unsafe or improper condition is noted. If an
unsafe or improper condition is noted, the Consumer should then immediately contact the facility
where the product was installed or A.W.E. Tuning directly.
Please contact the original place of purchase for any warranty claims or explanations of this document.